Kaizens

Heavy Wrinkel observed.
Location of component in either way which would result in flange shift & component rejection.
Hole mis-match by 6 to 7 mm b/w mating pressings.
Hole Shift in Ref. top 8216.
Rejection of GPL 112 in bending operation.
Frequent tighting required to Allen bolts of intermidiate shaft bush.
During trimming operation comp.mis-placed.(Joggle location).
Held milling operation missing in HBFT-384(M & M)( 2 PCS found at final packing stage).
Dimension 41-0/+2 observed undersize40 mm in SHBC-375, rear SPG BKT- telco.
Bending of pulley mounting area(RIB) occures during processing in cmb-delphi(Customer Complaint).
Increase & Decrease in heating time & idle time. Case depth observed 0.9 mm against 1.5 to 2.3 mm.
Hardness variation(Low hardness) in Spring pin during induction hardening process hardness observed 52 HRC inplace required hardness 55 HRC.
U-BOLT - Stem difference problem.
Heater marks at bend portion of U.BOLT as current exceed from the sepcified current 125 AMP on heater machine.
Chances of mixing of rejected switches due to operator careleeness.
Mismatching of key number in different product of same kit.
Part damage and in complete assy. of gasket.
Hole mismatched or without hole job also formed in forming tool.
Chances of operation missing (Batch Marking).
Exceesive movement of key due to wrong body plate fitted in steering lock.
Pierce II operation missing.
Opposite side bracket welding.
Nut missing.
Nut missing-1.
Unsafe act may lead to an accident.
Component can be located in wromg direction.
Mixup of both models body.
Tumber dics spring missing in inner cylinder sac.
To avod the possibility of injury to the operator' hand.
To avoid the possibility of injury to operator.
To avoid the possibility of injury to operator's hand.
To avoid the possibility of injury to operator-1.
To eliminate rejection due to missing operation in socket ball stud.
Spring found in excess length and not parted.
Buckling of 2 wheeler shock absorber spring during setting & safity in setting.
Mix-up of un ground Spgs.
Customer complaint. Gromet pressing done by holding the coverplate assy manually leading to crack.
HCB Teeth damage.
Gromet Crack - Customer complaint. Gromet pressing done by holding the coverplate assy manually leading to crack.
Wrong arrow position feeding at facing.
IN IA - 801 Bore closing can be done without six hole punching operation in top.
3070 DS Bore punching can be in wrong direction.
Eyelet closing can take place without fireing insertion.
Missing of operation due to tool breakage.
Leak NG pieces going to next stage.
Undersized or oversized gutter.
Rejection due to wrong position of notch.
CSK depth shallow - Not to Specification.
RIMS of different heights are fed into the press manually resulting in'Wrong press dics into RIM' Assembly operation.
Dowel hole position withrespect to marking position could not be maintained.
All ingredients not mixed in the compound.
Screw deformation due to low induction hardeness.
Screw balldia undersize F.
Chance of Accident.
Oil hole Bloackage.
Products supplied to the customer were not properly De-Burred.
Complaints while packing.
Complaints while packing-1.
Spring part no. E16-4601.having middle 0.d.lower than required limit.which cannot be checked by ring guage while coiling to control it.
Wrong arrow position feeding at facing.
Jobs without hole & hole dbl wise shift in Bush.
Customer complaint-Wrong fitment of damper bkt.(AT to CT).
To eliminate inconsistency of stay bkt. position in cal-115 chassis.
Steering lock bkt.Shift.Operator not able to detect shift.
To eliminate wrong fitment of bkt.31161099(AT - BOXER) instead of bkt.DM161008(CT Boxer).
The fitment of cable spring not possible in BOXER AT/CT veh.in final assy. due to absences of dia 6.0 mm hole.
Customer complainet due to wrong location or shifted of leg guard bracket in chassis.
Customer complainet due to missing of leg guard bracket in chassis.
Customer complainet due to wrong location of cross assly at forward tacking stage.
Customer complainet wrong fitment of damper bkt.(AT to CT)
Customer complainet due to wrong location or shifted of leg guard bracket in chassis-1.
Steering lock bkt.shift.Operator not able to detect shift-1.
To eliminate shifting of tank bkt(DL161086) at CT-CELL.
To eliminate rejection of Rear Assy (LH / RH) due to shifting seat rail pipe ( DD 161002 / 3).
The fitment of BKT step [30161066] Difficult on F 45 tack welding.
Customer Complaint of Outlet pipe pressing In Escort 440 radiator due to less gap bet. Cowl & pipe.
M6 nut thread damage.
Timer starts after reaching at 350 degree C.
To Reduce Lead Time And Cost Of Ctitical Itmes – Eicher bend pipes.
Standard Radiators.
Warranty filure in long run due to less surface contact hence strength.
Standard Radiators-1.
Flux enters in tube @ 20 mm due to capilary action hence air velocity required for air blow was higher.
Arrow marking in wrong direction.
At M&M assembly line fitment problem noticed for leaf spring 310N due to center bolt head diameter observed 16mm against spec.14mm.
Arjun Upper Column And Jkt. Tube Assy. Welding O. D. fouling in Jkt. Tube Inclination of Col. O.D. w.r.t Brg. I.D. Spline Shaft O.D. Over Size.
Rubber bush comes out from jacket tube crimping.
Column comes due of jacket tube during fitment on vehicle.
RC Gauge not answering because of burr getting clogged.
Crushing of panel when put in the wrong position in spot welding.
Discontinuation of rubber feed to Calendar causing Quality Defect.
Rubber accumulation between Take away conveyor and Cooling Rack.
Water dispensing over the washing machine during inspection due to wrong position of the washer lid.
PCB assembly – in circuit tester (ICT) Jig top plate misalignment, causing damage to PCB components. (Rejection).
Difficult to monitor process temperature.
Accidental flip over of plating masks during plating of crystal blanks.
Loss of productivity due to the unnecessary regenerationof Cryo pump resulted from the tripping of the Cryo pump, when mains voltage goes below 217 V.
Gas supply stops in between the operation affecting the quality of the entire batch.
Resistor value variations, contamination of conductor when air pressure and dew point of air drops.
Solder dip rejections of resistor networks (RN) due to late solder top up.
Premix charging through side door can cause accident.
Damage of washing machine nozzles.
Damage of washing machine nozzle & flywheel due to lateral shift.
Oil lubrication hole not opening in idler gear bore during drilling operation.
Counter shaft gear damaged in hobbing operation.
Burrs not being removed from tapped holes.
Ica Car – Monogram punched on reverse side on the job.
Breakage of Centre drill on Centering & Facing machine results in component rejection.
Missing of bearing during ‘Bearing Pressing and Caulking’ into Jacket Pipe Operation.
In notch drilling machine last lining in the magazine got damaged while loading in the jig.
Lodige mixer skip hoist moving up when safety door is in open condition.
Lodige mixer skip hoist rope loosening.
Slab pusher was getting damaged by cutting saw, while feeding last lining.
Accident due to hand injury during ram down. & safety door not closed.
Chipping scrap due to components overflowing and falling on the floor.
Motor tripping after product changeover.
Short length of tapping operation.
Machine stops due to less amount of material.
Drill breakage leading to drill missing.
Component loaded wrongly leading to accidents machine down for six hours & components rejected.
Hydraulic pump operated without operating circulating pump.
Permanent marker used on white board.
Mudgun over travelling and hitting the wall.
In pickling line, while doing manual banding work the operation of recoiler is possible which is an unsafe operating condition.
In slitting line, Over arm falls on the recoiler when lowered and damages the equipment (Recoiler drum & overarm separator discs.).
In coil tilting machine, Horn shaft moves beyond its limit and causes downtime.
In slitting line, some times the recoiler drum is operated in collapsed condition against expanded condition, resulting in equipment down time.
In picking line, some times the edge trimmer heads are moved beyond the extreme positions resulting in damage to the equipment (threaded bushes and lead screw).
In slitting line, while doing in process inspection activities the plant can be operated which is an unsafe working condition.
Speaker box assembly line-after packing, if the speaker box is not removed in time, it will fall on the floor and get damaged.
Wrong label pasted on product boxes which was detected at customer's end.
No indication of elapsed curing time of silver epoxy dispensed crystal elements.
Over & Under Filling of Sand flopper against required 75 kg.
Drill Chipping scrap occurs due to continuous use of blunt drills.
Malfunctioning occurs in pneumatic system resulting in scrap.
Mudgun kept in hot zone too long.
Wrong assembly due to interchange of wires during soldering.
Transformer soldering to PCB during manual soldering leads get shorted, leading to rejections.
Wrong part assembled in Clutch Disc Sub-Assly.
Missing washers.
Knuckle without Split-Pin-Hole is sometimes assembled to Inter Tube.
Wrong Damper assembled to FSS (Front Strut Support).
Defective parts (with mounting hole missing) assembled.
Wrong lever assly. in Door Lock.
B.D. Lock Assy. get rejected due to variation in angle of push lever.
Short tracks (circuit) of PCB assembly during soldering.
Wrong Assembly of Bias Cutter Trolley.
Wrong fitment of tappet valve in Head. Exhaust value at inlet port & Inlet. Valve at exhaust part.
Mixing of unpunched pressing with punched pressing.
Reverse forging of Bi-metal valves.
Defective part (Inlet port block).
Two valve parts assembled instead of one.
Over/under torquing in bolts of F/C seats.
Ball missing.
Final Tightening of Nut is not done sometimes.
Operator forgets to tighten all bolts of recliner assembly & loose bolts go to customers.
Missing of torquing of mounting bolts in Axle Assy.
Tread rejection due to cushion missing.
Burner tripping due to lowered diesel level.
Customer complaints due to rejected devices getting mixed up with good pieces.
Detect absence of groove by stopping bearing without groove.
Induction Heating machine runs without Cooling water sometimes.
Choking of Syphon due to low air pressure in the line.
Mixup of other type of Pistons.
Material despatched without inspection of harness.
Frame tube length variation in bending operation.
Steering column – Trimming operation missing.
Wrong positioning of Rear Housing.
Nconsistent billet temperature from Induction Billet Heater.
Detection of each defective component for number of serration teeth as per specification.
To ensure number of serration teeth as per specification to avoid further machining on defective component.
Operator forgets the cycle time for coating.
Inconsistent billet temperature from Induction Billet Heater.
Manual control of cycle time of the pre-curing ovens causes over pre-curing/under pre-curing resulting crack in product.
Component without grooving operation loaded.
"Without Keyway" component going to Assly shop.
Disc mounting hole drilling operation is missing (Customer complaint.
Disc mounting hole drilling operation.
Rod sometimes is not tested on Weld Strength Testing Machine.
Engine ceasing due to improper Lubrication in cylinder head drain hole missing.
Rejection of crankshaft assy due to missing key way operation in crankshaft.
Oil hole missing problem.
Embossing Operation Missing in Stud Floor Brkt.
Case Differential with notch missing operation goes to the customer.
Defective part (inlet port block).
To prevent detect for tapping missing during tapping of 14 holes.
C' case Magneto side going for Assly. without Main shaft Needle Roller Bearing.
Item # 1, Missing in assembling OPN.(Resulting into customer complaint.
Snap Ring missing.
Oil leakage due to oil seal missing during assembly.
Missing of ? 5 pin during case diff. Assembly.
Operator misses the circlip while fitting operation in Column Shaft Assy.
O ring not assembled.
Missed operation of cup plug assembly.